Systems and methods for hinged bedding assemblies

ABSTRACT

In many aspects, the systems and methods described herein include mattress having a top sleeping layer disposed on top of a support layer. The support layer includes polyurethane foam having channels comprising one or more slits on both sides of a surface to act as hinges for articulation. The channels may be aligned with the joints of the articulated sections of the foundation or frame of the adjustable bedding assembly. When the sections articulate about the joints, the channels allow the overlying top layer to conform to the sections while reducing wear and tear therein.

FIELD OF THE INVENTION

This invention relates to mattresses and mattress assemblies foradjustable beds, and more generally, assemblies for adjustablefurniture.

BACKGROUND OF THE INVENTION

Adjustable bed constructions typically include a mattress placed on topof a rigid foundation having articulating arms that move the entiremattress or portions thereof. The foundation includes a plurality ofsections that may be adjusted relative to one another such thatmattresses that are disposed on the foundation, bend and conform withthe articulated sections of the rigid foundation to provide comfort ortherapy as needed. However, repeated bending and articulation of themattresses near the joints of the articulated sections often cause wearand tear and reduce the lifespan of the mattresses.

For example, in conventional innerspring mattresses, springs distortnear the joints and at the edges from bending. Conventional innerspringmattresses include stabilizing and reinforcing structures such as sturdyborder wires along top and bottom edges to prevent sagging and increaselifespan. These stabilizing and reinforcing structures make the mattressuniformly resilient in the direction required to support the horizontalbody. However, these structures resist bending as required on anarticulated bed. Consequently, such stabilizing and reinforcingstructures are limited in their use in articulated beds. As a result,articulated mattresses of the prior art may have a shorter useful lifeand do not provide the uniform body support necessary for thisapplication.

Conventional foam mattresses that are currently being used in adjustablebed constructions, also suffer from the similar drawbacks. Inparticular, foam mattresses are typically disposed on top of the rigidarticulated foundation and experience significant wear and tear near thejoints that compromise the integrity of the foam structure and reduceits lifespan. In addition, since the mattresses are artificially forcedto bend along the joints of the foundation, they tend to not fullyconform with the articulated sections. Consequently, portions of thefoam mattress, when articulated, may be raised or lowered unevenly orslide out of position.

Accordingly, there is a need for an improved mattress construction thatcan be used in an articulated bed.

SUMMARY OF THE INVENTION

The systems and methods described herein are directed to mattresses andmattress assemblies for adjustable beds, and more generally, articlesfor adjustable furniture. For purposes of clarity, and not by way oflimitation, the systems and methods may be described herein in thecontext of providing mattresses for adjustable bedding assemblies.However, it may be understood that the systems and methods describedherein may be applied to provide for any cushioning article associatedwith any type of adjustable furniture. For example, the systems andmethods of the invention may be used to provide futon mattresses, seatcushions, including automotive seat cushions, sofa cushions, pillows andother such cushions and supports.

More particularly, the mattresses described herein include a top layerdisposed on top of a support layer of polyurethane foam having channelsincluding one or more slits on both sides of its surface to act ashinges for articulation. The channels may be aligned with the joints ofthe articulated sections of the foundation or frame of the adjustablebedding assembly. When the foundation sections articulate about thejoints, the channels allow the mattress to conform to the sections whilereducing wear and tear therein. The channels are beneficial in that theyhelp minimize tearing near the bending regions.

In one aspect, the mattress of the present invention comprises a toplayer, and a support foam layer disposed below the top layer. Thesupport foam layer has a top surface, a bottom surface, a first sidewall, and a second side wall. Also, the support layer includes a firstchannel extending from the first side wall to the second side wall alongthe bottom surface, and a second channel extending from the first sidewall to the second side wall along the top surface. In certainembodiments, the mattress includes a third layer disposed between thesupport foam layer and the top layer, and may further include aplurality of layers disposed between the support foam layer and the toplayer, wherein at least one of the layers includes at least one of foamor springs. In addition, the top layer and/or at least one of theplurality of layers may include a spring layer having foam disposed inbetween a plurality of coil springs, wherein the spring layer compriseswrapped coil spring. Furthermore, the top layer and/or at least one ofthe plurality of layers and support foam layer includes at least one ofpolyurethane, latex, and visco foam.

As described above, the support foam layer of the mattress of thepresent invention includes a first channel and a second channel. Incertain embodiments, the support foam layer includes more than twochannels. Additionally, at least one of the first channel and the secondchannel has a depth that extends partially into the thickness of thesupport foam layer, extending about 1/15 to about 13/15 of the thicknessof the support foam layer. The first channel and the second channel mayhave a depth from about 1/10 to 7/10 of the thickness of the supportfoam layer, or about ¼ to about ½ of the thickness of the support foamlayer. The depth of at least one of the first channel and second channelextends perpendicular from the bottom and top surface, respectively, ofthe support foam layer. In certain embodiments, the channel issufficiently deep to allow flexing and to reduce mechanical stress onthe point of articulation of the mattress. Further, at least one of thefirst channel and the second channel has a width that allows forconsistent firmness in the top layer, and may be about ⅛ inch to about1.5 inches wide. The width of the channels may range from about ⅙ inchto about 1 inch, or about ¼ inch to about ½ inch.

In certain embodiments, at least one of the first channel and the secondchannel in the support foam layer may comprise a plurality of parallelslits, wherein the slits are spaced apart by about ⅛ inch to about 2inches. Alternatively, the distance between the slits may range fromabout ⅙ inch to about 1.5 inches, or about ⅓ inch to about 1 inch.Likewise, the plurality of parallel slits of at least one of the firstchannel and the second channel has a depth that extends partially intothe thickness of the support foam layer, wherein the depth of each slitis the same as or different from each other. The dimensionalrequirements that lend to the functional characteristics of the channelsdescribed above also apply to the plurality of slits of each channel.

DETAILED DESCRIPTION OF THE ILLUSTRATED EMBODIMENT

The foregoing and other objects and advantages of the invention will beappreciated more fully from the following further description thereof,with reference to the accompanying drawings wherein;

FIG. 1 is a perspective view of an adjustable mattress, according to anillustrative embodiment of the invention.

FIG. 2 illustrates an unassembled view of the mattress of FIG. 1,according to an illustrative embodiment of the invention.

FIG. 3 is a perspective view of the mattress in operation, according toan illustrative embodiment of the invention.

FIGS. 4A and 4B depict a cross-section view of mattresses, according toan illustrative embodiment of the invention.

FIG. 5 depicts a cross-section view of mattresses, according to anillustrative embodiment of the invention.

DESCRIPTION OF THE PREFERRED EMBODIMENT

To provide an overall understanding of the invention, certainillustrative embodiments will now be described, including an articulatedhinged mattress having channels in the support foam layer. However, itwill be understood by one of ordinary skill in the art that the systemsand methods described herein may be adapted and modified for othersuitable applications and that such other additions and modificationswill not depart from the scope hereof.

In many aspects, the systems and methods described herein provide anarticulated mattress suitable for use with an adjustable mattressfoundation. The mattress described herein includes one or more paddinglayers disposed on top of a support foam layer. The top surface and thebottom surface of the support foam layer include channels comprising oneor more slits that may function as hinges for articulation. The channelsmay help to reduce wear and tear on the hinging portions of themattress.

More particularly, FIG. 1 depicts an adjustable mattress 100, accordingto an illustrative embodiment of the invention. Although the mattress100 is depicted as having a rectangular plan, it will be understood thatthe mattress may be sized and shaped as desired without departing fromthe scope of the invention. The mattress 100 includes a top layer 106and a middle layer 104 that are disposed on a support foam layer 102.The mattress 100 may have standard dimensions, with a length 114, awidth 108, a side 116, and another side 118 corresponding to at leastthe dimensions of a king, queen, double, or twin mattress. The supportfoam layer 102 includes a channel 110 formed on the bottom surface and achannel 112 formed on the top surface. The channels 110 and 112 mayextend from the sidewall 116 to the sidewall 118 in transverse directionalong the mattress 100. In an exemplary bed assembly, the mattress 100may be disposed on top of an adjustable foundation or frame havingarticulating sections. The channels 110 and 112 may be aligned with oneor more joints of the articulating sections of the foundation. Duringoperation, as the articulating sections of the foundation are movedrelative to one another, one or more regions of the support foam layer102 articulate about the channel 110 and/or channel 112, therebyallowing one or more regions of the top layer 106 and middle layer 104to be raised or lowered. In one example, the channels 110 and 112 arepositioned near the head and foot regions, respectively, of themattress. In such an example, the head portion may be raised and thefoot portion may be lowered to bring a person from a laying downposition to a sitting position. In certain embodiments, as describedfurther with reference to FIG. 4A, the support foam layer 102 includesan additional channel near the neck region to offer added head/necksupport for the user.

The support foam layer 102 may be a polyurethane foam. The support foamlayer 102 may be formed from other suitable materials without departingfrom the scope of the invention. In certain embodiments, the supportfoam layer 102 is formed from a material having an IFD (or ILD) valuefrom about 30 to about 50. The support foam layer 102 may have a weightand/or density of about 1 lb to about 5 lbs. In certain embodiments, thesupport foam layer 102 may have a weight and/or density of greater than2 lbs. The support foam layer 102 may have weight, rigidity, density,and flexibility values as desired depending on the nature of theapplication. In certain embodiments, the support foam layer 102 includespolyurethane foam having a substantially consistent and relativelyuniform density across the length and width of the layer. As notedearlier, the support foam layer 102 includes a channel 110 formed on thebottom surface and a channel 112 formed on the top surface. The channels110 and 112 may be formed by cutting, slicing or carving portions of thesupport foam layer 102 as desired, or by molding foam with channelstructures. The channels 110 and 112 may include one or more slits thatallow the support foam layer to articulate about region of the channels110 and 112, thereby minimizing stretching and tearing of the supportfoam layer 102 or layers 104 and 106. Certain illustrativecharacteristics of the channels in the support layer will be furtherdescribed with reference to FIG. 2.

In certain embodiments, the top layer 106 and/or the middle layer 104includes the mattress core. In such embodiments, the mattress coreincludes an innerspring mattress comprising coils, encased coils (suchas POCKETED COIL® springs) or Marshall Coils. The top layer 106 and/orthe middle layer 104 may include polyurethane materials. In certainembodiments, the top layer 106 and/or the middle layer 104 include foam,visco-elastic foam and/or latex foam. The top layer 106 and/or themiddle layer 104 may include a combination of an innerspring mattresscore combined with foam material, as described with reference to FIG. 5.

The top layer 106 and/or the middle layer 104 may be formed from a sheetof fabric, felt, or polymer, a cotton, nylon, or polyester batting, orfrom a layer of foam, plastic, polymer, natural fiber, synthetic fiber,or any other material or a combination thereof. In one optionalembodiment, the mattress 100 may have cover panel that comprises anon-quilted mattress cover with an optional smooth sleeping surface. Inthis embodiment, a multi-layer, typically three layer, crowned mattresspanel may be provided over the upper surface of the mattress. Forexample, a crowned cover panel may be formed from a top fabric layer, anintermediate filler layer and a backing layer. Optionally, there may bea layer of flame retardant material or combination of materials. Ineither embodiment, the top layer may be a fabric layer of cotton, linen,synthetic fibers or some other material of combination of materials.

The top layer 106, middle layer 104 and any additional layers may beformed from any suitable materials without departing from the scope ofthe invention. In certain embodiments, the mattress 100 further includesone or more filler layers. The filler layer can be formed from anypadding material, such as foam, cotton batting, gel, latex foam,visco-elastic foam or other known padding materials and or combinationof padding materials. Optionally, the filler layer provides a layer ofconventional filling and padding material that may be laid over themattress.

An optional fire resistant layer may be disposed in mattress 100 inbetween at least two of the top layer 106, middle layer 104 and supportfoam layer 102. The fire resistant layer optionally extends over the atleast entire upper surface of the mattress panel and around the bordersof the panel. The flame resistant material may be any suitable material,such as for example polyaramid material (such as KEVLAR™), PET(polyester) binder fiber, organophosphorous materials, halogenatedorganic materials (typically halogenated with chlorine or more popularlybromine) or nitrogen based compounds. Commercially available materialsare sold under the trade names NOMEX, KEVLAR™, INDURA and the actualmaterial employed may depend upon the particulars of the application,including mattress type (e.g. open coil, encased coil, foam, water),mattress size, material costs and other such design considerations.

Under the fire resistant layer, a backing layer may be attached. Thebacking layer may be formed from a sheet of material, such as naturalfibers such as cotton or linen, aluminum, fiberglass, synthetic fibersor a mixture thereof. These three layers may be joined together to forma crowned panel and that panel may be placed over the upper surface andjoined to the mattress to provide a smooth sleeping surface. Inaddition, the mattress 100 typically includes a fabric or plasticcovered structure having an internal construction configured to providecomfort for a user resting on the surface. Finally, the mattress 100 mayalso include a removable cover that helps prevent allergens on thesurface.

FIG. 2 illustrates an unassembled view 200 of the mattress 100 having atop layer 106, a middle layer 104 and a support layer 102. The supportlayer 102 includes a top surface 224 and bottom surface 226, and has athickness 210 which may be about 1 inch to about 8 inches. In certainembodiments, the support layer 102 has a thickness from about 2 inch toabout 7 inches, or about 3 inches to about 5 inches. The first channel110 lies at a distance 206 away from the edge of the head region 212,and the second channel 112 lies at a distance 208 away from the edge ofthe foot region 214 of the mattress 100. In one example, the firstchannel 110 may be from about 25 inches to about 40 inches from the headregion 212, or about 29 inches to about 38 inches, or further, about 33inches to about 35 inches. Similarly, the second channel 112 may be fromabout 22 inches to about 37 inches from the foot region 214, or about 25inches to about 34 inches, or further, about 28 inches to about 31inches. The distance 206 or 208 may be adjusted to suit the dimension,mechanical, and/or functional requirements of the mattress. For example,the distances 206 and 208 may be selected based on whether the mattressis sized as a king, queen or twin. In certain embodiments, thesedimensions may be customized to an individual's body size.

As shown, the first channel 110 extends from sidewall 116 to sidewall118 creating a slit 228 along the bottom surface 226. Likewise, thesecond channel 112 extends from sidewall 116 to sidewall 118 creating aslit 230 along the top surface 224 of the support foam layer 102. Incertain embodiments, the channels may include a plurality of parallelslits which may also further delay tearing, as will be described withreference to FIGS. 4A and 4B. Further, the first channel 110 cuts intothe support foam layer 102 to a height 202, and therefore depth, fromthe bottom surface 226. Similarly, the second channel 112 cuts into thesupport foam layer 102 to a depth 220 from the top surface 224. Incertain embodiments, the depth of each slit may be about 1/15 to about13/15 of the thickness of the support foam layer 102. Alternatively, therange of the depth may be from about 1/10 to 7/10, or about ¼ to about ½of the thickness of the support foam layer 102. In one example, asupport layer 102 that is about 4 inches thick may have a slit rangingin depth from about ¼ inch to about 3.5 inches. The depths 202 and 220may be selected as desired to allow for the articulation of the mattresswhile also maintaining the integrity of the hinge areas, especially whenused in combination with an articulating platform/foundation. Further,the depth of each slit 202 and 220 may be the same or different for oneor more slits in either channel 110 and 112.

The channels 110 and 112 have a width 204 and 222, respectively, and maybe from about ⅛ inch to about 1.5 inches. The width of the channels mayfurther range from about ⅙ inch to about 1 inch, or about ¼ inch toabout ½ inch. The width 204 and 222 of slits may be selected as desiredto allow, among other things, improved articulation of the mattress byminimizing soft spots on the top layer 106 of the mattress, andimproving the integrity of the mattress. In certain embodiments, theaxes along which the slits 228 and 230 extend on the top surface 224 andthe bottom surface 226 are perpendicular with respect to the sides 116and/or 118 of the mattress 100.

As such, the slits 228 and 230 in channels 110 and 112, respectively,have a depth and width to allow for ease of articulation suitable forthe dimensions and material of the mattress. Additionally, thedimensions of the depth and width of the channels, in combination withtheir placement at distances 206 and 208 from the head and foot regions,respectively, may be determined based on the application, degree andnature of the articulation needed. Moreover, in an alternativeembodiment of the invention, the mattress is suited to offer betterconformability when used in combination with an articulated base, aswill be described with reference to FIG. 3.

Depicted in FIG. 3 is an adjustable bed assembly 400 in operation,according to an illustrative embodiment of the invention. The bedassembly 400 includes a mattress 100 (FIG. 1) disposed on an adjustablefoundation 401 comprising an articulating platform having articulatingsections 402, 412 and 414 connected to a rigid base 404 via theactuating system 420 and 422. As shown, the channels 110 and 112 open toallow, among other things, articulation of the mattress and to reducethe mechanical stress that results on the pressure points 408 and 410when the mattress is caused to articulate. The channels may also act tolocalize the pressure points 408 and 410 to the joints of thearticulating sections 416 and 418, thereby minimizing unwanted tearingthat may otherwise happen in several places. Additionally, the channelsmay ensure suitable flexing of the mattress to better conform with thearticulating platform. For example, this feature may be particularlyappreciated by users of different weights and sizes. The channelsencourage the full range of articulation without the need for a heavieruser's mass to conform the mattress against the articulating sections402, 412, 414, for example. As such, small and large users mayexperience similar levels of comfort during articulation that may beindependent of their size and weight. In certain embodiments, arubberized material may be sprayed at the point 408 and 410 to furtherretard tearing. The rubberized material may be applied to the channels110 and 112 at, among other places, along the interior of the slits.

In certain embodiments, the mattress 100 may be adjusted to otherpossible configurations to allow the user to choose the position of thehead and foot of the bed for maximum comfort. In an alternativeembodiment of the invention, the actuating system 420 and 422 may beprogrammed to an array of custom configurations.

FIGS. 4A and 4B illustrate a cross-section views of mattresses in whichthe support foam layer 502 or 702 includes channels having a pluralityof parallel slits 504 and 506 or 704 and 706. Mattress 600 and 700 ofFIGS. 4A and 4B may be similar to mattress 100 of FIG. 1. Similarly, themattress 600 or 700 includes a top layer 106, a middle layer 104, and asupport foam layer 502 or 702 comprised of foam material as describedpreviously.

More particularly, FIG. 4A depicts the channels 504 and 506 that extendthrough the support foam layer 502 having a thickness 510 of about 1inch to about 8 inches. Alternatively, the support layer 502 may have arange of thickness, from about 1.5 inches to about 6.5 inches, or about2 inches to about 5 inches. As shown, each channel includes two slits:slits 602 and 604 included in channel 504, and slits 608 and 610included in channel 506. The slits included in each channel may beparallel to each other and are separated by a distance that is measuredfrom the inner adjacent edges of each slit, as shown in 606 and 612. Inone example, the distance between the slits may be from about ⅛ inch toabout 2 inches. The distance between the slits may range from about ⅙inch to about 1.5 inches, or about ⅓ inch to about 1 inch, and may varyaccording to the dimensions of the mattress, and the degree ofarticulation desired. Further, similar to that described in FIG. 2, eachslit of the channel has a height 614 that is a measure of its depth intothe thickness of the support foam layer. By way of illustration, theheight of only one slit 614 is depicted. However, all slits thatcomprise the channels have a height, and therefore depth, in the supportfoam layer 502. In certain embodiments, the depth of each slit may ormay not be the same for all slits. Each slit may have a width which maybe determined according to the criteria described in FIG. 2.Additionally, although two slits are illustrated for each channel inFIG. 4A, the invention may include a plurality of slits per channel, asshown in FIG. 4B. In certain embodiments, the support foam layer 502 mayinclude an additional channel 508. The channel 508, includes twoparallel slits 616 and 618, and lies at the head/neck region of themattress. However, the placement of additional channels is notrestricted to this configuration; instead, additional channels may beplaced to suit the needs of the user and/or the configuration of thefoundation. Slit dimensions for all channels may be selected as desireddepending on at least the criteria of the aforementioned descriptions.

By way of example, FIG. 4B depicts a mattress having three parallelslits per channel in its support foam layer. Slits 716, 718 and 720 formchannel 704 and slits 722, 724, and 726 form channel 706. As indicated,the middle slit 718 or 724 has a height 710 or 714, respectively, and isflanked by shorter slits 716 and 720 or 722 and 726, respectively. Asdescribed previously, since each height defines the depth of each slitinto the support foam layer, the middle slit in this example forms thedeepest groove. The slits on either side may be of the same or differentdepths. As previously described, the distances between slits aredesigned to be sufficiently wide to allow flexibility, while adequatelynarrow to maintain the integrity of the mattress as well as to preventsoft spots on the top layer 106. In certain embodiments, theconfiguration of the multi-slit channels 704 and 706 may allow forsmaller distances between slits to minimize the likelihood of theformation of soft spots on its top layer while maintaining the range ofmotion needed for the mattress. Moreover, the added slits may act toreduce the mechanical stress on the points of articulation since thepressure may be distributed to several slits.

In certain embodiments, the one or more top layers disposed on thesupport foam layer may include features to ease articulation of themattress along the hinge channels. In one example, the top layer mayinclude reinforcing support structures disposed near the region of thechannels. FIG. 5 illustrates a cross section view of a mattress 800having a top layer 801 that includes an innerspring constructioncombined with one or more layers of foam 806. In one example, the toplayer 801 is disposed on a middle foam layer 804. Alternatively, the toplayer 801 and the middle foam layer 804 may be unitarily formed as acomposite layer, disposed on top of the support foam layer 802. Thesupport foam layer 802 includes channels 814 and 816 to allowarticulation of the mattress 800. The support foam layer 802 may besimilar to support foam layer 102 of FIG. 1.

The top layer 801 may include an innerspring encased coil constructionhaving a plurality of coils 812 that are disposed in pockets 808 and810. In certain embodiments, the coils 812 may be arranged in rows alonga sheet of pocket material (e.g., upholstery or fabric). The pocketmaterial may then be wrapped around the coils 812 and sealed (e.g., byheat-sealing techniques) along lines 818 to seal the coils 812 in thepockets. The encased coils may be arranged on a foam block 804, which inturn may be disposed on the support foam layer 802.

In certain embodiments, foam blocks 806 may be disposed in between aplurality of coil springs, and may be aligned above one or more channels814 and 816 on the support foam layer 802. In certain embodiments, theencased coils may be attached to the foam blocks 806 to provide furtherreinforcement. In other embodiments, foam material is poured into theinnerspring coil construction to fill one or more gaps between thecoils. In such embodiments, the foam material may be poured in liquid orgel form and may subsequently cure to provide an integrated foam andspring top layer 801.

In certain embodiments, the mattress 800 includes one or more sidewallsdisposed or attached to at least one of the top layer 801, middle layer804 and support layer 802. The sidewalls may include foam. In suchembodiments, the sidewalls may include one or more channels formedthereon. The channels may be configured so as to form a contiguouschannel(s) with the support foam layer. The sidewalls may be sized,shaped and cut as desired depending on the dimensions of the mattress.The sidewalls may or may not include one or more channels that arealigned with the one or more channels on the support foam layer 802. Thesidewalls may or may not include one or more channels that are notaligned with the one or more channels on the support foam layer 802. Thechannels on the sidewalls may be sized and shaped similar to thechannels on the support foam layer 802.

Variations, modifications, and other implementations of what isdescribed may be employed without departing from the spirit and scope ofthe invention. More specifically, any of the method, system and devicefeatures described above or incorporated by reference may be combinedwith any other suitable method, system or device features disclosedherein or incorporated by reference, and is within the scope of thecontemplated inventions. The systems and methods may be embodied inother specific forms without departing from the spirit or essentialcharacteristics thereof. The foregoing embodiments are therefore to beconsidered in all respects illustrative, rather than limiting of theinvention. The teachings of all references cited herein are herebyincorporated by reference in their entirety.

1. A mattress, comprising a top layer, and a support foam layer disposedbelow the top layer, having a top surface, a bottom surface, a firstside wall, a second side wall, wherein the support foam layer includes afirst channel extending from the first side wall to the second side wallalong the bottom surface, and a second channel extending from the firstside wall to the second side wall along the top surface.
 2. The mattressof claim 1, further comprising a third layer disposed between thesupport foam layer and the top layer.
 3. The mattress of claim 1,further comprising a plurality of layers disposed between the supportfoam layer and the top layer.
 4. The mattress of claim 3, wherein atleast one of the layers includes at least one of foam or springs.
 5. Themattress of claim 3, wherein a layer includes a spring layer having foamdisposed in between a plurality of coil springs.
 6. The mattress ofclaim 5, wherein the spring layer comprises wrapped coil spring.
 7. Themattress of claim 3, wherein at least one of the layers and support foamlayer includes at least one of polyurethane, latex, and visco foam. 8.The mattress of claim 1, wherein at least one of the first channel andthe second channel comprise a plurality of parallel slits.
 9. Themattress of claim 8, wherein the plurality of slits are parallel to eachother, spaced apart by about ⅓ inch to about ½ inch.
 10. The mattress ofclaim 1, wherein at least one of the first channel and the secondchannel has a width that allows for consistent firmness in the toplayer.
 11. The mattress of claim 10, wherein at least one of the firstchannel and the second channel is about ⅓ inch to about ¾ inch wide. 12.The mattress of claim 1, wherein at least one of the first channel andthe second channel has a depth that extends partially into the thicknessof the support foam layer.
 13. The mattress of claim 12, wherein thedepth of at least one of the first and the second channel extends about⅓ to about ½ of the thickness of the support foam layer.
 14. Themattress of claim 8, wherein at least one of the first channel and thesecond channel comprises a plurality of parallel slits having a depththat extends partially into the thickness of the support foam layer. 15.The mattress of claim 14, wherein the depth of the parallel slits arethe same as or different from each other.
 16. The mattress of claim 12,wherein the depth of at least one of the first channel and secondchannel extends perpendicular from the bottom and top surface,respectively, of the support foam layer.
 17. The mattress in claim 1,wherein the channel is sufficiently deep to allow flexing and reducemechanical stress on the point of articulation of the mattress.
 18. Themattress in claim 1, wherein the support foam layer is sufficientlyrigid/firm to accommodate the load of the top layers.